Ingersoll-Rand ML250K Installationsanleitung

Form P6554

PARTS, OPERATION AND MAINTENANCE MANUAL

for

AIR CHAIN HOIST MODELS*

ML250K ML5OOK ML1OOOK

250 kg (1/4 ton) 500 kg (1/2 ton) 1000 kg (1 ton)

ML250KR ML500KR

250 kg (1/4 ton) 500 kg (1/2 ton)

Spark Resistant Spark Resistant

ML250KS

250 kg (1/4 ton)

Slow Speed

ML500KS

500 kg (1/2 ton)

Slow Speed

(Dwg. MHTPA0456)

ML1OOOKS

1000 kg (1 ton)

Slow Speed

* Capacities of hoists are in metric tons (1 metric ton = 2200 Ibs.)

READ THIS MANUAL BEFORE USING THESE PRODUCTS. This manual

contains important safety, installation, operation and maintenance infor-

mation. Make this manual available to all persons responsible for the

operation, installation and maintenance of these products.

Do not use this hoist for lifting, supporting, or transporting people or lifting or supporting

loads over people.

Always operate, inspect and maintain this hoist in accordance with American National

Standards Institute Safety Code ( ASME B30.16) and any other applicable safety codes and

regulations.

Refer all communications to the nearest Ingersoll-Rand Material Handling Office or

Distributor.

Form P6554

Edition 9

June 1994

03531324

MATERIAL HANDLING

This manual provides important information for all

personnel involved with the safe installation, operation and

proper maintenance of this product. Even if you feel you

arc familiar with this or similar equipment, you should read

and understand this manual before operating the product.

Danger, Warning, Caution and Notice

Throughout this manual there are stepsand procedures

which, if not followed, may result in a injury. The follow-

ing signal words are used to identify the level of potential

hazard.

Safety Summary

Danger is used to indicate the

presence of a hazard which will

causesevere injury, death, or

substantial property damage if the

warning is ignored.

Warning is used to indicate the

presence of a hazard which can

causesevere injury, death, or

substantial property damage if the

warning is ignored.

Caution is used to indicate the

presence of a hazard which will or

can causeminor injury or property

damage if the warning is ignored.

Notice is used to notify people of

installation, operation, or mainte-

nance information which is impor-

tant but not hazard-related.

Do not use this hoist or attached equipment for lifting,

supporting, or transporting people or lifting or support-

ing loads over people.

Powered hoists are designed to provide a 5 to 1 safety

factor. The supporting structures and load-attaching

devices used in conjunction with this hoist must provide

adequate support to handle all hoist operations plus the

weight of the hoist and attached equipment. This is the

customer’s responsibility. If in doubt, consult a

registered structural engineer.

Lifting equipment is subject to different regulations in

each country. These regulations may not be specified in

this manual.

The National Safety Council, Accident Prevention Manual

for Industrial Operations, Eighth Edition and other recog-

nized safety sources make a common point: Employees

who work near cranes or assist in hooking on or arranging

a load should be instructed to keep out from under the load.

From a safety standpoint, one factor is paramount: conduct

all lifting operations in such a manner that if there were an

equipment failure, no personnel would be injured. This

means keep out from under a raised load and keep out of

the intended path of any load.

Ingersoll-Rand Material Handling hoists are manufactured

in accordance with the latest ASME B30.16 standards.

The Occupational Safety and Health Act of 1970 generally

places the burden of compliance with the owner/employer,

not the manufacturer. Many OSHA requirements are not

concerned or connected with the manufactured product but

are, rather, connected with the final installation. It is the

owner’s responsibility and user’s responsibility to deter-

mine the suitability of a product for any particular use. It is

recommended that all applicable industry, trade associa-

tion, federal, state and local regulations be checked. Read

all operating instructions and warnings before operation.

Rigging: It is the responsibility of the operator to exercise

caution, usecommon senseand be familiar with proper

rigging techniques. SeeASME B30.9 for rigging informa-

tion, American National Standards Institute, 1430 Broad-

way, New York, NY 10018.

This manual has been produced by Ingersoll-Rand to

provide dealers, mechanics, operators and company

personnel with the information required to install, operate,

maintain and repair the products described herein.

It is extremely important that mechanics and operators be

familiar with the servicing procedures of these products, or

like or similar products, and are physically capable of

conducting the procedures. These personnel shall have a

general working knowledge that includes:

1. Proper and safe use and application of mechanics

common hand tools aswell as special

Ingersoll-Rand or recommended tools,

2. Safety procedures, precautions and work habits

established by accepted industry standards.

Ingersoll-Rand can not know of, nor provide all the

procedures by which product operations or repairs may be

conducted and the hazards and/or results of each method. If

operation or maintenance procedures not specifically

recommended by the manufacturer are conducted, it must

be ensured that product safety is not endangered by the

actions taken. If unsure of an operation or maintenance

procedure or step, personnel should place the product in a

safe condition and contact supervisors and/or the factory

for technical assistance.

The following warnings and operating instructions have

been adapted in part from American National (Safety)

Standard ASME B30.16 and are intended to avoid unsafe

operating practices which might lead to personal injury or

property damage.

Ingersoll-Rand recognizes that most companies who use

hoists have a safety program in force in their plants. In the

event you are aware that some conflict exists between a

rule setforth in this publication and a similar rule already

setby an individual company, the more stringent of the two

should take precedence.

Safe Operating Instructions are provided to make an

operator aware of dangerous practices to avoid and are not

necessarily limited to the following list. Refer to specific

sections in the manual for additional safety information.

1. Read the manufacturer’s operating instructions before

operating the hoist.

2. Never lift a load greater than the rated capacity of the

hoist (unless for test purposes).

3. Never use the load chain as a sling.

4. Never operate the hoist with twisted, kinked or

damaged chain.

5. Be certain the load is properly seatedin the saddle of

the hook.

6. Do not use load chains asa ground for welding. Do

not attach a welding electrode to a hoist or sling chain.

7. Do not use the up and down stops asa means of

stopping a hoist. The up and down stops are emer-

gency devices only. Keep hands and clothing free from

the throttle lever.

8. Do not leave a load suspended for extended periods.

9. Always stand clear of the load path.

IO. Never use the hoist for lifting or lowering people, and

never stand on a suspended load.

11. Never carry loads over people.

12. Before each shift, check the hoist for wear or damage.

Check brakes, limit stops, etc.

13. Periodically, inspect the hoist thoroughly and replace

worn or damaged parts.

14. Follow the lubrication instructions.

1.5. Do not attempt to repair load chain or hooks. Replace

them when they become worn or damaged.

16. Never operate a hoist when the load chain is not

centered under the hook. Do not “side pull” or “yard”.

17. Always rig the hoist properly and carefully.

18. Easethe slack out of the load chain when starting a

lift. Do not jerk the hoist load.

19. Keep the load chain clean and well lubricated. Do not

20. Be certain there are no objects in the way of a moving

load.

21. Be certain the air supply is shut off before performing

maintenance on the hoist.

22. Do not swing a suspended load.

23. Keep the load block overhead when not in use.

24. Properly secure hoist before leaving it unattended.

25. Only allow personnel trained in safety and operation

on this product to operate the hoist.

26. Avoid collision or bumping of hoists.

27. Do not operate a hoist if you arc not physically fit to

do so.

28. Pay attention to the load at all times when operating a

hoist.

29. Never splice a hoist chain by inserting a bolt between

links or by any other means.

30. Do not force a chain or hook into place by hammering,

and never insert the point of the hook into a chain link.

31. Do not allow the chain to be exposed to extremely

cold weather. Do not apply loads to a cold chain.

drag the load chain or hook on the floor.

Each hoist is supplied from the factory with the warning

tag and label shown. If the tag or label are not attached to

your hoist, order a new tag or label and install it. Seeparts

list in parts section. Read and obey all warnings and other

safety information attached to this hoist. Tag and label may

not be shown actual size.

DO NOT USE

LOWERING PEOPLE

Table 1

Speed with Rated Load Speed with Half Load Speed with No Load

Hoist Model Rated No.

No. Capacity Chain fpm m/m fpm m/m m/m

(kg) fpm

Falls UP down up down up down up down up down up down

ML250KS 40 90 12.2 27.4 53 71

16.1 21.6

ML250K 250 1 101 117 30.8 35.7 145 III 44.2 33.8 171 99 52.1 30.1

ML250KR 26 38 7.9 11.6 34 36

ML500KS 22 66 6.7 20.1 30 44

ML500K 500 55 97 16.8 29.6 80 72 24.4 22.0 1O6

ML500KR 2 13 20 4.0 6.1 17 18

ML1000KS 11 33 3.4 10.0 15 22 4.6 6.7 22

I000 2

ML1000K 28 49 8.5 14.9 40 36 12.2 11.0

Performancefiguresbasedon 70CFM (45 CFM for MLKS andMLKR

Hoists) at 90 psi (620 kPa) air supply at hoist inlet. Pendant

control models use approximately 4 SCFM more air.

Model Code Explanation

Series

=M Example: ML500 KR-2C 10-5 BZ

Link Chain Type = L

Hoist Capacity

250K = 2.50kg - l/4 metric ton (550 lb)

500K = 500 kg - l/2 metric ton (1100 lb)

lOOOK = 1000 kg - 1metric ton (2200 lb)

Spark Resistant

R = Spark Resistant (ML250K and ML500K only)

S = Slow Speed Spotting

1 = Pull Chain

2 = Pendant

3 = 2 Motor Pendant

4 = 3 Motor Pendant

Suspension

A = Fixed Lug

C = Swivel Top Hook

D = Plain Rigid Trolley (Tapered Wheels for I-Beam)

DT = Plain Rigid Trolley (Flat Tread Wheels)

F = Hand Chain Geared Trolley (Tapered Wheels for I-Beam)

FT = Hand Chain Geared Trolley (Flat Tread Wheels)

M = Plain Hook-on Trolley (Tapered Wheels for I-Beam)

MT = Plain Hook-on Trolley (Flat Tread Wheels)

H = Vane Motor Driven Trolley, Pendant Control,

(2) Wheel Drive (Tapered Wheels for I-Beam)

HT = Vane Motor Driven Trolley, Pendant Control,

(2) Wheel Drive (Flat Tread Wheels)

Length of Lift

xx = 10 ft. (3 m)

= Specify Length

Pendant Drop

5 = 5 ft. (1.5 m)

xx = Specify Length

BZ = Zinc Plated Chain

BB = Bullard Burnham Hook(s)

BR = Bronze Hook(s)

Prior to installing the hoist, carefully inspect it for possible

shipping damage.

Hoists are supplied fully lubricated from the factory.

Lubrication of the load chain is recommended before initial

hoist operation.

Owners and users are advised to examine specific,

local or other regulations, including American

National Standards Institute and/or OSHA Regulations

which may apply to a particular type of use of this

product before installing or putting hoist to use.

A falling load can cause injury or death. Before

installing, read “SAFETY INFORMATION”.

Hoist

Make certain your hoist is properly installed. A little extra

time and effort in so doing can contribute a lot toward

preventing accidents and helping you get the best service

possible.

Always make certain the supporting member from which

the hoist is suspended is strong enough to support the

weight of the hoist plus the weight of a maximum rated

load plus a generous factor of at least 500% of the com-

bined weights.

If the hoist is suspended by a top hook, the supporting

member should rest completely within the saddle of the

hook and be centered directly above the hook shank. Do

not use a supporting member that tilts the hoist to one side

or the other.

Hook Mounted Hoist Installation

Place hook over mounting structure. Make sure hook latch

is engaged.

Trolley Mounted Hoist Installation

(Refer to Dwg. TPA825-2)

When installing a trolley on a beam, measure the beam

flange and temporarily install the trolley on the hoist to

determine the exact distribution and arrangement of the

spacers.The distance between the wheel flanges should be

3/16 in. to l/4 in. (4.76 mm to 6.35 mm) greater than the

width of the beam flange. The number of spacers(257)

between the trolley side plate (250) and the mounting lug

on the hoist must be the samein all four locations in order

to keep the hoist centered under the I-beam. The remaining

spacersmust be equally distributed on the outside of the

side plates. (For additional information refer to Installation

and Maintenance Manual Form P6609 for Vane Motor

Driven Trolleys.)

I SPACER MINIMUM

REQU I RED

(SEE INSTRUCTIONS)

MLK Hoist Plain Rigid Trolley

(Dwg. TPD909)

At least one Mounting Spacer (257) must he used

between the head of each Trolley Bracket Bolt (255)

and the Trolley Bracket (250) and between each Trolley

Bolt Nut (256) and the Trolley Bracket. Failure to do

this could cause the hoist to fall when used improperly.

Torque the Trolley Bolt Nuts (256) to 150 ft-lb (203 N.m).

When installing the hoist and trolley on the beam, make

certain the side plates are parallel and vertical. After

installation, operate the trolley over the entire length of the

beam with a capacity load suspended4 to 6 inches (I 0 to

15cms) off the floor.

To avoid an unbalanced load which may damage the

trolley, the hoist must be centered under the trolley.

Trolley wheels ride on the top of the lower flange of

the beam.

Chain Container

When installing a fabric chain container on an MLK hoist,

refer to drawings TPB605-2 and TPD580 in the parts

section.

AIR OUT

Make certain to adjust the balance chain so that the

chain container does not contact the load chain.

Allow chain to pile naturally in the chain container.

Piling the chain carelessly into the container by hand

may lead to kinking or twisting that will jam the hoist.

1. Check the chain container size to make sure the length

of load chain is within the capacity of the chain

container. Replace with a larger chain container, if

required.

2. Attach the chain container to the hoist.

3. Run bottom block to lowest point and run hoist in up

direction to feed the chain back into the container.

Air System

The supply air must be clean, lubricated and free from

water or moisture. A minimum of 90 psi (6.2 bar/620 Kpa)

at the hoist motor is required to provide rated hoist

capacity.

Air Lines

The inside diameter of the hoist air supply lines must not

be smaller than l/2 in. (13 mm) basedon a maximum of 50

ft. (15 m) between the air supply and the hoist. Contact the

factory for recommended air line sizes for distances greater

than 50 ft. (15 m). Before making final connections, all air

supply lines should be purged before connecting to unit

inlet. Supply lines should be asshort and straight as

installation conditions will permit. Long transmission lines

and excessive useof fittings, elbows, tees,globe valves etc.

cause a reduction in pressure due to restrictions and surface

friction in the lines. If quick-disconnect fittings are used at

the inlet of the hoist, they must have at least a 3/8 in. (9.5

mm) air passage.Use of smaller fittings will reduce

performance.

Always use an air line filter and lubricator with an

MLK hoist.

REGULATOR

LUBRICATOR FILTER

(Dwg. MHTPA0191)

Air Line Lubricator

(Ref. Dwg. MHTPA0191)

Always use an air line lubricator with these hoists. Use a

lubricator having an inlet and outlet at least aslarge asthe

inlet on the hoist motor. Install the air line lubricator as

close to the air inlet on the hoist motor aspossible. Refer to

“ACCESSORIES” in the parts section for the recom-

mended Filter-Lubricator-Regulator.

Lubricator must be located no more than 10 ft. (3 m)

from the motor.

The air line lubricator should be replenished daily and set

to provide lubrication at a minimum rate of 1to 3 drops per

minute adjusted at maximum hoist speed,of SAE 10W oil

or a good grade of hydraulic oil. A fine mist will be

exhausted from the throttle control valve when the air line

lubricator is functioning properly.

Do not use automotive type detergent oil. Detergents

will delaminate the motor vanes and cause premature

failure.

Air Line Filter

(Ref. Dwg. MHTPA0191)

It is recommended that an air line strainer/filter be installed

asclose aspractical to the motor air inlet port to prevent

dirt from entering the motor. The strainer/filter should

provide 10micron filtration and include a moisture trap.

Clean the strainer/filter monthly to maintain its operating

efficiency.

Moisture in Air Lines

Moisture that reachesthe air motor through the supply

lines is the chief factor in determining the length of time

between service overhauls. Moisture traps can help to

eliminate moisture. Other methods, such asan air receiver

which collects moisture before it reaches the motor or an

aftercooler at the compressor that cools the air prior to

distribution through the supply lines, are also helpful.

Shut off air supply before filling air line lubricator.

The Inlet Strainer (42 or 344) must be installed on the

hoist. Failure to do so may result in a hoist malfunction.

The Bleed Adjustment Screws (35 or 336) used on hoists

with a pendent control are factory adjusted to provide

optimum control at 90 psig (6.2 bar/620 kPa) air pressure.

If the hoist is used with other air supply pressures, the

Bleed Adjustment Screws may require readjustment.

Adjustment of Bleed Screws on Pendent

Control Models

For maximum performance and control, adjust the bleed

screws (35 or 336) asfollows:

Loosen the Adjustment Screw Locknut (36 or 337).

Back out the Adjustment Screw (35 or 336) approxi-

mately one third (l/3) of a turn.

While fully depressing the Pendent Throttle Lever

(205) and holding it in that position, turn in the

Adjustment Screw until the Piston Rod fully retracts.

This adjustment will provide a good balance of

spotting control and maximum hoist speed.If better

spotting control is desired, slowly back out the

Adjustment Screw a little at a time until the spotting

control is suitable.

Tighten the Adjustment Screw Locknut (36 or 337).

Storing the Hoist

1. Always store the hoist in a no load condition.

2. Wipe off all dirt and water.

3. Oil the load chain, hook pins and hook latch.

4. Place in a dry location.

5. Plug hoist air inlet port.

6. Before returning hoist to service follow instructions

for Hoists not in Regular Service in the “INSPEC-

TION’ section.

The four most important aspectsof hoist operation are:

1. Follow all safety instructions when operating hoist.

2. Allow only people trained in safety and operation on

this product to operate hoist.

3. Subject each hoist to a regular inspection and mainte-

nance asoutlined in ASME B30.16.

4. Be aware of the hoist capacity and weight of load at all

times.

Operators must be physically competent. Operators must

have no health condition which might affect their ability to

act, and they must have good hearing, vision and depth

perception. The hoist operator must be carefully instructed

in his duties and must understand the operation of the hoist,

including a study of the manufacturer’s literature. The

operator must thoroughly understand proper methods of

hitching loads and should have a good attitude regarding

safety. It is the operator’s responsibility to refuse to operate

the hoist under unsafe conditions.

Initial Operating Checks

Hoists are tested for proper operation prior to leaving the

factory. Before the hoist is placed into service the follow-

ing initial operating checks should be performed.

After installation of trolley mounted hoists, check to

ensure the hoist is centered below the trolley.

Check for air leaks in the supply hose and fittings to

pendant, and from pendant to manifold.

When first running the hoist or trolley motors some

light oil should be injected into the inlet connection to

allow good lubrication.

When first operating the hoist and trolley it is recom-

mended that the motors be driven slowly in both

directions for a few minutes.

Operate the trolley along the entire length of the beam.

Inspect hoist and trolley performance when raising,

moving and lowering test load(s). Hoist and trolley

must operate smoothly and at rated specifications prior

to being placed in service.

Check that trolley (if equipped) and hook movement is

the samedirection asarrows or information on the

pendant control.

Raise and lower a light load to check operation of the

hoist brake.

Check hoist operation by raising and lowering a load

equal to the rated capacity of the hoist a few inches

(cm) off the floor.

10. Check operation of limit devices.

11. Check to seethat the hoist is directly over the load. Do

not lift the load at an angle (side pull or “yard”).

12. Check to seethat the hoist is securely connected to the

overhead crane, monorail, trolley or supporting

member.

13. Check to seethat the load is securely inserted in the

hook, and that the hook latch is engaged.

Only allow personnel trained in safety and operation

of this product to operate the hoist and trolley.

The hoist is not designed or suitable for lifting,

lowering or moving persons. Never lift loads over

people.

Hoist Controls

MLK Two Lever Pendant

Two lever pendants provide operation of the hoist only. For

units with powered trolleys a four lever pendant is re-

quired.

RAISE

LOAD

(Dwg. MHTPA0427)

The hook latch is intended to retain loose slings or

devices under slack conditions. Hook latches are not

intended to be an anti-fouling device, so caution must

be used to prevent the latch from supporting any of the

load.

Refer to Form P6778 for information on Pendant Throttle

Handle Assemblies for two and three motor functions.

There are two types of inspection, the frequent inspection

performed by the operator and periodic inspections

performed by personnel trained in the operation and repair

of this hoist.

Careful inspection on a regular basis will reveal potentially

dangerous conditions while still in the early stages,

allowing corrective actions to be taken before the condition

becomes dangerous.

Any deficiency revealed through inspection must be

reported to an appointed person. A determination must be

made asto whether a deficiency constitutes a safety hazard

before resuming operation of the hoist.

Records and Reports

Some form of inspection record should be maintained for

each hoist, listing all points requiring periodic inspection.

A written report should be made monthly on the condition

of the critical parts of each hoist. These reports should be

dated, signed by each person who performed the inspec-

tion, and kept on file where they are readily available to

authorized personnel.

Frequent Inspection

On hoists in continuous service, frequent inspection should

be made at the beginning of each shift. In addition, visual

inspections should be conducted during regular service for

any damage or evidence of malfunction.

1. OPERATION. Check for visual signs or abnormal

noises (grinding etc.) which could indicate a potential

problem. Make

sure

all controls function properly and

return to neutral when released. Check chain feed

through the hoist and bottom block. If chain binds,

jumps, is excessively noisy or “clicks”, clean and

lubricate the chain. If problem persists, replace the

chain. Do not operate the hoist until all problems have

been corrected.

2. HOOKS. Check for wear or damage, increased throat

width, bent shank or twisting of hook. Replace hooks

which exceed the throat opening discard width

specified in Table 2 (see Dwg. MHTPA0040) or

exceed a IO” twist (seeDwg. MHTPAOlll). If the

hook latch snapspast the tip of the hook, the hook is

sprung and must be replaced. Refer to the latest

edition of ASME B30.10 “HOOKS” for additional

information. Check hook support bearings for

lubrication or damage. Ensure they swivel easily and

smoothly.

3. UPPER AND LOWER LIMIT DEVICE. Test

operation with no load slowly to both extremes of

travel. Upward travel must stop when the bottom

block or stop buffer on chain hits hoist limit arm.

Downward travel must stop when the loop at the

unloaded end of the chain decreasesand activates the

limit arm.

. Throat Width

(Dwg. MHTPA0040)

Table 2

ML 1000K and ML I000KS l-1/4 31.8 I-7/32 31.0

ML250KR and ML500KR I-7/32 31.0 l-5/16 33.4

Twisted

DO NOT USE Normal

Can Be Used

(Dwg. MHTPAO111)

4. AIR SYSTEM. Visually inspect all connections,

fittings, hoses and components for indication of air

leaks. Repair any leaks found. Check and clean the

filter in the Inlet Nipple, if equipped, and the strainer

in the Inlet Strainer (42).

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